Volvo L120F Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L120F Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions L120F Wheel Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Volvo L120F Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,571 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword........2
0 - GENERAL........3
03 - SPECIFICATIONS........4
Tightening torques........7
Oil sump; tightening torque ........18
Lubrication system; specifications........20
Fuel system; tightening torques........21
Thermostat; specifications ........23
Engine; specifications _........24
Speed sensor; specifications........25
Valve system specifications_........26
Engine; capacities ........27
Fuel system; specifications........28
Fuel tank; volume........29
Fuel feed pump; specifications........30
Thermostat; specifications........31
Cooling system; volume........32
Reversible cooling fan; tightening torques........33
Temperature limits for cooling fan speed; specifications........34
Cooling fan rpm; specifications_........35
Engine; specifications_........36
Speed sensor; tightening torque........38
Turbocharger; tightening torques........39
Battery; specifications........40
Battery; weight........41
Electrical system; specifications........42
Preheating; specifications........43
Alternator 080 A; specification........44
Front and rear axles; tightening torque........45
Front and rear axles; specifications_{002-12-13}........46
Front and rear axles; specifications_{002-11-50}........47
Front and rear axles; volume........48
Hydraulic transmission; volume_{002-10-49}........49
Hydraulic transmission; volume_{002-10-26}........50
Hydraulic transmission; specifications........51
Hydraulic transmission; tightening torques_{002-09-16}........53
Hydraulic transmission; tightening torques_{002-08-52}........54
Propeller shaft; tightening torque........55
Parking brake; specifications_{002-07-52}........56
Parking brake; specifications_{002-07-29}........57
Brake valve; tightening torques........58
Wheel brake; tightening torques........59
Wheel brake; specification........60
Brake system; specifications........61
Brake accumulator; specifications........62
Steering cylinder; tightening torque........63
Steering; specifications........64
Secondary steering pump; specifications........65
Control valve; lever steering (CDC); specifications........66
Lever steering (CDC); specifications........67
Rear axle mounting; volume........68
Frame joint; tightening torques........69
Frame; tightening torque........70
Wheels; specifications........71
Wheel; tightening torque........72
Cab; tightening torque........73
Air conditioning; refrigerant; weight_{002-00-38}........74
Air conditioning; refrigerant; weight_{002-00-14}........75
Air conditioning; tightening torques........76
Hydraulic system; volume........77
Control valve; specifications........78
Hydraulic pump (P001); specifications........79
Hydraulic pump (P002); specifications........80
Hydraulic pump (P003); specifications........81
Servo system; specifications........82
Boom Suspension System; specifications........83
Cooling fan rpm; specifications........84
Boom Suspension System; tightening torques........85
003rd_4th hydraulic function; specifications........86
Lift cylinder; tightening torques........87
Tilt cylinder; tightening torques........89
Conversion tables ........91
Hydraulic connections; tightening torques........95
Conversion tables........98
Engine; specifications ........102
07 - STANDARD TIME........104
Operation numbers for additional work........105
08 - TOOL........107
Infrared Thermometer........108
E-2017........112
E-2015........113
E-2001........115
E-2000........117
E 1708; Checking point........119
E1706........121
09 - MISCELLANEOUS........122
Basic checks........123
1 - STANDARD PARTS; SERVICE........125
16 - LUBRICANT; FUEL; OTHER FLUID........126
Recommended lubricants; oils........127
Coolant........129
Alternative fuels........134
17 - SERVICE........137
Working on the electrical system of the machine........139
Repairing hydraulic system........140
Cleanliness; brake and hydraulic systems........141
Electric welding ........142
Charging of batteries........144
Steering system working pressure; checking and adjusting ........145
Transmission oil pressure; checking_{01-39-57}........148
Transmission oil pressure; checking_{01-39-30}........153
Hydraulic pump; max working pressure; checking and adjusting ........158
Maintenance service; first 1000 hours_{01-35-41}........160
Maintenance service; first 1000 hours_{01-35-06}........170
Maintenance service; every 4000 hours_{01-34-10}........180
Maintenance service; every 4000 hours_{01-33-17}........210
Maintenance service; every 4000 hours_{01-32-19}........240
Service position 1_{01-30-33}........270
Brake discs; measuring wear........272
Wheel brake; specification_{01-29-23}........274
Boom suspension accumulator; checking and adjusting........275
Hydraulic pump P1 and P2; checking........279
Maintenance service; daily........281
Maintenance service; every 50 hours........283
Maintenance service; every 250 hours........287
Maintenance service; every 500 hours........294
Maintenance service; every 1000 hours_{01-24-41}........309
Maintenance service; every 1000 hours_{01-24-00}........327
Maintenance service; every 2000 hours_{01-23-05}........345
Maintenance service; every 2000 hours_{01-22-16}........373
Maintenance service; every 2000 hours_{01-21-24}........401
Maintenance service; every 6000 hours........429
Hydraulic oil level; checking........431
Hydraulic oil; changing........432
Hydraulic oil return filter; replacing_{01-18-52}........434
Hydraulic oil return filter; replacing_{01-18-25}........436
Engine oil level; checking........437
Engine oil filter; replacing........438
Hydraulic pump; max working pressure; checking and adjusting........440
Transmission oil pressure; checking_{01-16-12}........442
Transmission oil pressure; checking_{01-15-37}........447
Steering system working pressure; checking and adjusting........452
Parking brake; manually releasing_{01-14-15}........455
Parking brake; manually releasing_{01-13-48}........457
Towing........460
Electric welding........462
19 - GENERAL........463
CE-marking; EMC-directive........464
Safety concerns everybody!_{01-10-16}........468
Safety concerns everybody!_{01-09-52}........472
Checking function........474
Safety when handling the machine........475
Safety rules when servicing........480
Service position 2_{01-07-44}........483
Service position 1_{01-07-16}........485
Working under raised boom........487
Fire prevention measures........489
Some simple rules regarding tyre handling........493
Safety when lifting and supporting complete machine........495
Safety when working with batteries........499
Starting with booster batteries........502
Safety when handling oils and fuel........504
Safety when handling accumulators........506
Safety when working on hydraulic systems........508
Safety when using lifting equipment........511
Checklist after a fire or heat exposure........513
Health hazards with paint; plastics and rubber........516
Waste handling........519
Environmentally safe handling........523
Environmentally hazardous fluids........526
Safety when working with air conditioning refrigerant........529
Working in environmentally contaminated areas........532
Decontamination........535
2 - ENGINE WITH MOUNTING AND EQUIPMENT........539
20 - GENERAL........540
Engine; description........541
E-ECU MID 128 pre-programmed; replacing........549
E-ECU MID 128 non-programmed; replacing........551
21 - ENGINE........553
Engine; capacities........554
Cylinder compression; VCADS Pro........555
Stall speed; VCADS Pro........556
Stall speed; checking........557
Idle; VCADS Pro........559
Engine rotation speed sensor; replacing........560
Engine; removing_{12-51-35}........562
Engine; removing_{12-51-07}........573
VCADS Pro; central systems updating; replace component........584
VCADS Pro; MID 128; programming E-ECU........585
Engine; installing_{12-49-39}........586
Engine; installing_{12-49-10}........596
Engine; specifications........607
Cylinder compression; testing_{12-48-06}........609
Valve system specifications........614
Valve system specifications_{12-46-36}........615
Valves; adjusting_{12-46-12}........616
Internal Exhaust Gas Recirculation (IEGR); description........624
Crankshaft seal; front; changing........630
Oil sump; tightening torque........637
22 - LUBRICATING SYSTEM........640
Lubricating system; description........641
Lubrication system; specifications........645
Lubrication oil pressure; checking with pressure gauge........646
23 - FUEL SYSTEM........648
Fuel system; description........649
Fuel system; tightening torques........651
Instructions for working with electronic fuel injection........653
Fuel system; bleeding........656
Carbon dioxide in fuel system; checking........658
Fuel feed pump; specifications........664
Fuel feed pump; description........665
Fuel filter; description........666
Feed pump pressure; checking........668
Fuel filter; checking........670
Fuel tank; volume........672
Fuel tank; removing........673
Fuel tank; installing........677
Fuel system; specifications........681
Injectors; description........682
Injectors; replacing_{10-40-19}........685
Injectors; replacing_{10-39-26}........687
High pressure fuel pump; checking........690
Fuel rail; description........694
Cylinder compression; VCADS Pro_{10-34-33}........696
Fuel rail pressure sensor; replacing_{10-34-05}........697
High pressure fuel pump; replacing........699
Fuel control valve (FCV); description........707
Fuel control valve (FCV); checking........709
Fuel control valve (FCV); replacing........713
Pressure relief valve (PRV); inspecting........716
High pressure fuel pump; description........719
Pressure relief valve (PRV); replacing........721
25 - INLET & EXHAUST SYSTEM........724
Intake and exhaust system; description_{05-39-27}........725
Intake and exhaust system; description_{05-38-45}........728
Turbocharger; description........731
Turbocharger; inspecting........733
Air cleaner; description........735
Preheating; description........737
Intercooler; description........739
26 - COOLING SYSTEM........740
Cooling system; description........741
Carbon dioxide in coolant system; checking........744
Cooling system; volume........750
Radiator; removing........751
Radiator; installing........757
Thermostat; specifications........762
Cooling fan; component location........763
Cooling fan; description........765
Reversible cooling fan; description........772
Cooling fan motor; description........776
Hydraulic pump (P003); specifications........778
Cooling fan rpm; specifications........779
Temperature limits for cooling fan speed; specifications........780
Reversible cooling fan; tightening torques ........781
Cooling fan hydraulics; function check........782
Pump 003 (P3) standby pressure; checking and adjusting (LS-line removed)........783
Pump 003 (P3); max pressure and fan speed; checking and adjusting........786
Cooling fan motor; replacing........790
Fan control valve; removing........798
Fan control valve; seal replacing........800
Fan control valve; installing........802
Reversible cooling fan; tightening torques........804
27 - ENGINE CONTROL........805
Accelerator Pedal_{05-06-56}........806
Accelerator Pedal_{05-06-36}........808
Hand Throttle........809
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........811
30 - GENERAL........812
Electrical system; work instructions........818
Electrical system; description........820
Software; description........822
Electronic control system; description........823
Communication with data buses ........825
VCADS Pro; Operations........827
Electrical system; specifications........829
Software parameters; description........830
General fault diagnosis information........845
Troubleshooting strategy........847
Collection of basic data........849
Information display; check ........852
SAE error codes; translation to error messages; general........854
Communication with data buses........857
Bus communication supervision........859
Conditions when checking........861
Lead and connector checks........864
Troubleshooting tools........869
Special tools for troubleshooting........871
VCADS Pro; Error codes........873
VCADS Pro service tool........876
CU6601; description and measuring........880
CU9901; description and measuring........885
E-ECU PID158; description and measuring........888
HE2501; description and measuring........890
MA2301-MA2306; description and measuring........892
MA2504; description and measuring........895
MA2601; description and measuring........897
MA2602; description and measuring........899
MA4603; description and measuring_{04-09-35}........901
MA4603; description and measuring_{04-08-04}........903
MA4603; description and measuring_{04-06-30}........905
MA5501; description and measuring_{04-04-55}........907
MA5501; description and measuring_{04-03-10}........910
MA5502; description and measuring........912
MA9101; description and measuring_{03-59-03}........914
MA9101; description and measuring_{03-57-31}........916
MA9106; description and measuring_{03-55-46}........918
MA9106; description and measuring_{03-54-16}........920
MA9141; description and measuring........922
MA9142; description and measuring........924
MO3301; description and measuring........926
MO6401; description and measuring........928
MO8707; description and measuring........930
Power supply ECC; description and measuring........933
Power supply E-ECU; description and measuring........935
Power supply I-ECU; description and measuring........937
Power supply V-ECU; description and measuring........939
Power supply V2-ECU; description and measuring........941
Power supply W-ECU; description and measuring........943
PWM2303; description and measuring........945
PWM2601; description and measuring........947
PWM6601; description and measuring_{03-30-22}........949
PWM6601; description and measuring_{03-29-19}........951
PWM6602; description and measuring_{03-28-06}........953
PWM6602; description and measuring_{03-27-00}........955
PWM9101; description and measuring_{03-25-43}........957
PWM9101; description and measuring_{03-24-38}........959
PWM9102; description and measuring_{03-23-22}........961
PWM9102; description and measuring_{03-22-22}........963
PWM9103; description and measuring_{03-21-06}........965
PWM9103; description and measuring_{03-20-01}........967
PWM9104; description and measuring_{03-18-39}........969
PWM9104; description and measuring_{03-17-33}........971
PWM9105; description and measuring........973
PWM9106; description and measuring........975
PWM9107; description and measuring........977
PWM9108; description and measuring ........979
PWM9133; description and measuring........981
PWM9108; description and measuring........983
R2701; description and measuring........985
RE01; description and measuring........987
RE02; description and measuring........989
RE05; description and measuring........991
RE06; description and measuring........993
RE08; description and measuring........995
RE09; description and measuring........997
RE10; description and measuring........999
RE15; description and measuring........1001
RE2501; description and measuring........1003
RE6401; description and measuring........1005
RE8701; description and measuring........1007
SAE J1708_1587 Information link; description and measuring........1009
SAE J1939_CAN1 Control link; description and measuring........1012
SAE J1939_CAN2 Control link; description and measuring........1015
SA-SF; description and measuring........1018
SE2202; description and measuring........1021
SE2203; description and measuring........1023
SE2205; description and measuring........1025
SE2301; description and measuring........1027
SE2302; description and measuring........1029
SE2303; description and measuring........1031
SE2309; description and measuring........1033
SE2501; description and measuring........1035
SE2502; description and measuring........1037
SE2507; description and measuring........1039
SE2508; description and measuring........1041
SE2601; description and measuring........1043
SE2602; description and measuring........1045
SE2603; description and measuring........1047
SE2606; description and measuring........1049
SE2701; description and measuring........1051
SE2702; description and measuring........1053
SE2703; description and measuring........1056
SE2704; description and measuring........1058
SE4213; description and measuring........1060
SE4307; description and measuring........1062
SE4608; description and measuring_{01-48-13}........1064
SE4608; description and measuring_{01-47-26}........1066
SE4901; description and measuring........1068
SE4903; description and measuring........1070
SE4904; description and measuring........1072
SE5201; description and measuring........1074
SE5202; description and measuring........1076
SE5205; description and measuring........1078
SE5218; description and measuring........1080
SE5503; description and measuring_{01-33-08}........1083
SE5503; description and measuring_{01-32-02}........1085
SE6401; description and measuring........1087
SE6403; description and measuring........1090
SE6407; description and measuring_{01-27-45}........1092
SE6407; description and measuring_{01-26-32}........1094
SE6601; description and measuring_{01-25-16}........1096
SE6601; description and measuring_{01-23-44}........1099
SE8503; description and measuring........1102
SE8702; description and measuring........1104
SE8706; description and measuring........1106
SE8708; description and measuring........1108
SE8709; description and measuring........1110
SE9101_SE9102; description and measuring........1113
SE9104; description and measuring........1116
SE9105; description and measuring........1118
SE9107; description and measuring........1120
SE9145; description and measuring........1122
SE9146; description and measuring........1124
SE9147; description and measuring........1126
SE9148; description and measuring........1128
SW3801; description and measuring........1130
SW4205_SW4206; description and measuring_{12-55-20}........1133
SW4205_SW4206; description and measuring_{12-53-44}........1136
SW4205_SW4206; description and measuring_{12-52-36}........1140
SW4208; description and measuring........1143
SW4209; description and measuring........1145
SW4210; description and measuring........1147
SW4211; description and measuring........1149
SW4212; description and measuring........1151
SW4217; description and measuring........1154
SW4220; description and measuring........1156
SW4221; description and measuring........1158
SW4222; description and measuring........1160
SW5501; description and measuring........1162
SW8701; description and measuring........1164
SW9143; description and measuring........1166
SW9148; description and measuring........1168
SAE error codes MID 128 Engine control unit (E-ECU)........1170
SAE error codes MID 140 Instrument control unit (I-ECU)........1171
SAE error codes MID 146 Electronic climate control unit (ECC)........1172
SAE error codes MID 187 Vehicle control unit (V-ECU)........1173
SAE error codes MID 249 Vehicle control unit 2 (V2-ECU)........1174
31 - BATTERY........1175
System voltage........1176
Key feed........1178
Battery; description........1180
Battery; weight........1181
Battery; specifications........1182
Battery condition; checking........1183
Battery; charging........1186
Batteries; replacing........1187
32 - ALTERNATOR; CHARGE REGULATOR........1189
Alternator 80 A; specification........1190
Alternator 80 A; description........1191
33 - STARTING SYSTEM........1192
Booting sequence........1193
Preheating; specifications........1195
Starter lock; replacing........1196
35 - LIGHTING........1198
Lighting; specifications........1199
Lighting; description........1200
36 - OTHER ELECTRICAL EQUIPMENT........1202
Reduced computer communication........1203
Interruption in computer communication........1205
Limp Home........1206
Intermittent wiper and washer........1207
Theft protection........1210
Connectors; overview........1212
Electronic climate control unit ECC; description........1216
Instrument control unit I-ECU; functional description........1218
Vehicle control unit V-ECU; description........1220
Vehicle control unit V2-ECU; description........1222
Engine control unit E-ECU; description........1224
I-ECU MID 140 non-programmed; replacing........1226
I-ECU MID 140 pre-programmed; replacing........1228
V-ECU MID 187 non-programmed; replacing........1230
V-ECU MID 187 pre-programmed; replacing........1232
37 - CABLE; FUSE; RELAY........1234
Electrical symbols and designations........1238
Cable and component designations........1242
Cable and component marking explanations ........1244
Cable and component marking explanations........1246
Component list Alternator; batteries; capacitors; electronic units; voltage outlet........1248
Component list; diodes........1252
Component list Fuses........1255
Component list Heating coils; instruments; service socket........1262
Component list Lights_{12-13-47}........1264
Component list Lights_{12-13-24}........1267
Component list Motors; resistors; monitoring system........1270
Component list PWM valves........1273
Component list Relays........1275
Component list Sensors........1278
Component list Signals; shift solenoids........1282
Component list Solenoid valves........1284
Component list Switches........1286
ECC; I_O list........1291
E-ECU; I_O list........1294
I-ECU; I_O list........1298
V-ECU; I_O list........1302
V2-ECU; I_O list........1306
Table of contents; wiring diagrams........1310
Wiring diagram 201........1312
Wiring diagram 202........1314
Wiring diagram 203........1317
Wiring diagram 204........1320
Wiring diagram 205........1323
Wiring diagram 206........1325
Wiring diagram 301_{12-04-01}........1328
Wiring diagram 301_{12-03-38}........1331
Wiring diagram 302_{12-03-04}........1334
Wiring diagram 302_{12-02-40}........1337
Wiring diagram 303........1340
Wiring diagram 304_{12-01-38}........1343
Wiring diagram 304_{12-01-15}........1346
Wiring diagram 305........1349
Wiring diagram 306_{12-00-08}........1352
Wiring diagram 306_{11-59-45}........1355
Wiring diagram 306_{11-59-22}........1358
Wiring diagram 308........1361
Wiring diagram 309........1364
Wiring diagram 310........1367
Wiring diagram 311_{11-57-21}........1370
Wiring diagram 311_{11-56-58}........1373
Wiring diagram 311_{11-56-35}........1376
Wiring diagram 312........1379
Wiring diagram 313........1382
Wiring diagram 314_{11-54-56}........1385
Wiring diagram 314_{11-54-33}........1387
Wiring diagram 315_{11-53-47}........1389
Wiring diagram 315_{11-53-20}........1392
Wiring diagram 315_{11-52-57}........1395
Wiring diagram 316........1398
Wiring diagram 317........1401
Wiring diagram 319........1405
Wiring diagram 401_{11-50-48}........1409
Wiring diagram 401_{11-50-21}........1412
Wiring diagram 402........1415
Wiring diagram 403_{11-49-19}........1417
Wiring diagram 403_{11-48-56}........1420
Wiring diagram 404........1423
Wiring diagram 407........1426
Wiring diagram 408_{11-47-15}........1428
Wiring diagram 408_{11-46-53}........1431
Wiring diagram 501_{11-46-18}........1434
Wiring diagram 501_{11-45-55}........1437
Wiring diagram 601_{11-45-20}........1440
Wiring diagram 601_{11-44-54}........1443
Wiring diagram 602_{11-44-20}........1446
Wiring diagram 602_{11-43-57}........1448
Wiring diagram 604_{11-43-23}........1450
Wiring diagram 604_{11-43-00}........1453
Wiring diagram 801........1456
Wiring diagram 802........1459
Wiring diagram 804_{11-41-01}........1462
Wiring diagram 804_{11-40-38}........1465
Wiring diagram 805_{11-40-03}........1468
Wiring diagram 805_{11-39-39}........1471
Wiring diagram 806_{11-38-53}........1474
Wiring diagram 806_{11-38-27}........1477
Wiring diagram 807........1480
Wiring diagram 901_{11-37-19}........1482
Wiring diagram 901_{11-36-55}........1485
Wiring diagram 902_{11-36-21}........1487
Wiring diagram 902_{11-35-57}........1490
Wiring diagram 903........1493
Wiring diagram 904_{11-34-48}........1496
Wiring diagram 904_{11-34-24}........1499
Wiring diagram 908........1502
Wiring diagram 909........1504
Wiring diagram 910........1507
Wiring diagram 911_{11-31-52}........1510
Wiring diagram 911_{11-31-29}........1513
Wiring diagram 912_{11-30-55}........1516
Wiring diagram 912_{11-30-31}........1519
Wiring diagram 913........1522
Wiring diagram 915........1524
Battery disconnect switch; description........1527
Chassis connection........1528
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM........1529
Instrument panels........1530
Middle instrument panel with warning lights........1532
Washer fluid level........1534
Fuel consumption........1535
Travelling speed........1538
Machine hours........1539
Information display; general........1540
Information display; start lockout........1543
Information display; operating display........1545
Information display; engine........1547
Information display; transmission........1550
Information display; hydraulics_{11-18-08}........1552
Information display; hydraulics_{11-17-31}........1555
Information display; axles _ brakes_{11-16-52}........1557
Information display; axles _ brakes_{11-16-16}........1559
Information display; electrical system_{11-15-36}........1561
Information display; electrical system_{11-15-14}........1563
Information display; vehicle info........1564
Information display; vehicle messages........1567
Information display; service_{11-13-40}........1568
Information display; service_{11-13-18}........1571
Information display; service mode_{11-12-38}........1573
Information display; service mode_{11-12-11}........1577
Information display; settings........1580
Information display; check........1582
Alarm; description........1584
Central warning........1586
39 - MISCELLANEOUS........1587
CareTrack W-ECU; description........1588
4 - POWER TRANSMISSION........1590
40 - GENERAL........1591
Error codes when calibrating ........1592
Front and rear axles; volume........1593
42 - TRANSMISSION; HYDRAULIC CONTROL........1594
Hydraulic diagram transmission - Image........1595
Hydraulic transmission; volume_{11-06-47}........1596
Hydraulic transmission; volume_{11-06-27}........1597
Hydraulic transmission; tightening torques_{11-05-56}........1598
Hydraulic transmission; tightening torques_{11-05-36}........1599
Hydraulic transmission; specifications........1600
Transmission; component location_{11-04-38}........1602
Transmission; component location_{11-04-06}........1610
Hydraulic transmission; description........1614
Transmission; removing........1621
Transmission; installing........1632
Hydraulic diagram transmission........1643
Transmission solenoid; replacing........1645
Transmission pressure sensor; replacing........1648
Transmission oil pressure; checking_{10-59-57}........1650
Transmission oil pressure; checking_{10-59-29}........1655
Transmission; functional check........1660
Seal for front output shaft; replacing_{10-58-36}........1661
Seal for front output shaft; replacing_{10-58-13}........1664
Seal for rear output shaft; replacing........1668
Transmission; calibration........1671
45 - PROPELLER SHAFT........1673
Propeller shaft; tightening torque........1674
46 - FRONT AXLE; REAR AXLE........1675
Drive axles; description........1676
Front and rear axles; tightening torque........1681
Front and rear axles; specifications........1682
Front and rear axles; volume........1683
Hub seal; replacing ........1684
Hub reduction; removing ........1701
Hub reduction; installing ........1703
Axle; removing........1705
Axle; installing........1708
Automatic differential brake; Limited Slip; description........1711
Hub reduction; removing........1713
Hub reduction; installing........1715
Hub seal; replacing........1717
Differential lock; description_{10-45-44}........1734
Differential lock; description_{10-45-22}........1736
Differential lock; adjusting........1738
Differential lock; function check........1744
49 - MISCELLANEOUS........1746
Heat exchanger; replacing........1747
5 - BRAKE........1752
50 - GENERAL........1753
Brake system; component location........1754
Braking system; description........1756
51 - WHEEL BRAKE........1762
Wheel brake; specification_{008-55-20}........1763
Wheel brake; specification_{008-54-55}........1764
Wheel brake; tightening torques........1765
Brake discs; measuring wear........1766
Brake discs; replacing_{008-53-01}........1768
Brake piston seals; replacing_{008-52-27}........1774
Brake disc; replacing_{008-51-50}........1777
Brake piston seals; replacing_{008-51-16}........1782
52 - HYDRAULIC BRAKE SYSTEM........1785
Brake system; specifications........1786
Brake system hydraulic function; checking........1787
Brake system circuit pressure; checking and adjusting........1791
Brake system; bleeding........1794
Brake system retardation function; checking........1796
Foot brake valve; description........1797
Brake valve; tightening torques........1799
Brake pedal; adjusting angle........1800
Foot brake valve; removing........1801
Foot brake valve removed; reconditioning........1804
Foot brake valve; installing........1807
Brake accumulator; description........1811
Brake accumulator; specifications........1813
Accumulator; checking........1814
Accumulator (removed) charging pressure; checking........1816
Accumulator; discarding........1818
55 - PARKING BRAKE........1821
Parking brake; specifications_{008-44-08}........1822
Parking brake; specifications_{008-43-49}........1823
Tightening torque........1824
Parking brake; component location........1825
Parking brake; component description........1827
Parking brake assembly; removing........1829
Parking brake; function description_{008-41-48}........1833
Parking brake; description_{008-41-25}........1838
Parking brake; adjusting........1842
Parking brake pads; checking........1845
Parking brake brake pads; replacing........1846
Parking brake; disassembling........1849
Parking brake; assembling........1851
Parking brake; installing........1854
Parking brake discs and seals; replacing........1857
Parking brake function; checking_{008-38-16}........1863
Parking brake function; checking_{008-37-57}........1864
6 - STEERING........1866
60 - GENERAL........1867
Steering system; component location........1868
Steering system; description........1871
Steering system function; checking........1877
64 - STEERING........1878
Steering; specifications........1879
Steering cylinder; description........1880
Steering valve; description........1882
Steering cylinder; tightening torque........1884
Shift valve; description ........1886
Steering system working pressure; checking and adjusting........1888
Shift valve; removing........1891
Shift valve; installing........1893
Steering cylinder; removing........1895
Steering cylinder removed; reconditioning excl replacing bearings........1899
Steering cylinder; installing........1903
Steering valve; replacing........1908
Steering cylinder; repacking........1911
Accumulator; discarding ........1914
Secondary steering pump; specifications........1916
Pressure monitor; description ........1917
Secondary steering pump working pressure; checking and adjusting........1918
66 - LEVEL STEERING........1920
CDC valve; lever steering; description........1921
Control valve; lever steering (CDC); specifications........1924
Lever steering (CDC); specifications........1925
Comfort drive control (CDC) angle sensor; changing........1926
Comfort Drive Control; servo pressure; checking........1929
Error codes when calibrating-........1931
Comfort drive control (CDC) solenoid valve; changing........1935
Lever steering (CDC) function; checking........1937
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT........1939
70 - GENERAL........1940
Frame; description........1941
71 - FRAME........1945
Frame; specifications........1946
Frame; tightening torque........1947
Counterweight; tightening torques........1948
74 - FRAME LINK........1949
Frame joint; tightening torques........1950
Frame joint; description........1951
75 - AXLE SUSPENSION........1953
Axle suspension; replacing bushes and seals........1954
Axle suspension; tightening torque........1963
77 - WHEELS; TRACKS; TYRE; HUB; DRUM........1964
Wheels; specifications........1965
Wheel; tightening torque........1966
Rear wheel; removing_{10-23-40}........1967
Rear wheel; removing_{10-23-18}........1969
Rear wheel; installing........1971
Front wheel; removing........1973
Front wheel; installing........1975
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE........1977
81 - CAB; NAKED; CANOPY........1978
Cab; tightening torque........1979
Cab; removing_{10-20-27}........1980
Cab; removing_{10-20-04}........1986
Cab; removing_{10-19-41}........1994
Cab; installing_{10-19-04}........2002
Cab; installing_{10-18-41}........2008
Cab; installing_{10-18-13}........2015
Cabin; tightening torques........2023
Viscous cab suspension; description........2024
Viscous cab suspension; changing one unit........2027
82 - ENGINE HOOD; MUDGUARD; FOOT STEP........2032
Engine hood; removing........2033
Engine hood; installing........2038
83 - DOORS; HATCH; COVER PLATE........2042
Door lock; replacing........2043
Door lock cylinder; replacing_{10-13-38}........2044
Door lock cylinder; replacing_{10-13-15}........2052
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING........2060
Windows; general........2061
Side window; replacing_{10-11-56}........2063
Windscreen; replacing_{10-11-27}........2073
85 - CAB INTERIOR; UPHOLSTERY........2083
Operator's seat; securing........2084
87 - AIR CONDITIONING UNIT........2086
Air conditioning; description........2087
ECC MID 146 non-programmed ECU; replacing........2092
ECC MID 146 pre-programmed ECU; replacing........2094
Troubleshooting; air conditioning unit (AC)........2096
Climate unit; removing........2100
Climate unit; installing........2108
Pause heater; description_{10-06-31}........2115
Pause heater; description_{10-06-09}........2117
Fan motor; replacing........2119
Air mix door actuator; replacing........2122
Heater core; replacing........2128
Heat control valve; replacing........2131
ECC (Electronic Climate Control); replacing........2133
Air conditioning; specifications........2138
Air conditioning; tightening torques........2140
Air conditioning; refrigerant; weight_{10-01-14}........2141
Air conditioning; refrigerant; weight_{10-00-55}........2142
Compressor; replacing incl draining and filling........2144
Receiver; replacing incl draining and filling_{09-59-50}........2148
Receiver; replacing incl draining and filling_{09-59-28}........2150
Evaporator; replacing incl draining and filling_{09-58-54}........2152
Evaporator; replacing incl draining and filling_{09-58-31}........2156
Expansion valve; replacing incl draining and filling........2163
Temperature sensor cooling system; replacing........2166
Condenser; replacing incl draining and filling........2172
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS........2175
90 - GENERAL........2176
Hydraulic diagram; complete 4 - Image........2177
Hydraulic diagram; complete 3 - Image........2179
Hydraulic diagram; complete 2 - Image........2181
Hydraulic diagram; complete 1 - Image........2183
Explanations to hydraulic diagram........2185
Safety when working on hydraulic systems........2194
Hydraulic system and component positions........2197
Hydraulic diagram; complete_{09-51-14}........2200
Hydraulic diagram; complete_{09-50-51}........2206
Hydraulic diagram; complete_{09-50-22}........2212
Hydraulic system; volume........2217
Hydraulic system; description........2218
Hydraulic system; bleeding........2221
V2-ECU; MID 249; changing non-programmed ECU........2224
V2-ECU; MID 249; changing pre-programmed ECU........2226
Accumulator; discarding ........2228
91 - WORKING HYDRAULIC; SERVO HYDRAULICS........2231
Working hydraulic system; component location........2234
Working hydraulic system; function description........2236
Error codes when calibrating........2240
Hydraulic oil tank; description........2244
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump........2246
Hydraulic connections; tightening torques........2248
Control valve; description_{09-44-02}........2250
Control valve; description_{09-43-33}........2254
Central valve; description........2258
Lift function; description_{09-42-32}........2260
Lift function; description_{09-42-09}........2264
Tilt function; description........2268
Floating position; description........2272
Control valve; specifications........2274
Back-up valve; checking and adjusting........2275
Shock valve lift function; checking_{09-39-51}........2278
Shock valve lift function; checking_{09-39-28}........2281
Shock valve; tilt function; checking........2284
Control valve; removing........2287
Control valve; installing........2291
Central valve; removing........2295
Central valve; installing........2297
Back-up valve; replacing........2300
Lift; solenoid valve; changing........2302
Lower; solenoid valve; changing........2304
Tilt in; solenoid valve; changing........2306
Tilt out; solenoid valve; changing........2308
Lift_lower; angle sensor; changing_{09-34-22}........2310
Lift_lower; angle sensor; changing_{09-34-00}........2313
Tilt in_out; angle sensor; changing........2316
Lift; functional check........2320
Tilt; checking........2321
Hydraulic pumps; description........2322
Hydraulic pump flow regulation; description........2324
Hydraulic pump (P1); specifications........2331
Hydraulic pump (P2); specifications........2332
Function times; specifications........2333
Lifting time; checking_{09-29-53}........2334
Lifting time; checking_{09-29-32}........2336
Hydraulic pump; standby pressure and working pressure; checking and adjusting........2337
Hydraulic pump P1 and P2; checking........2341
Hydraulic pump; standby pressure; checking and adjusting........2343
Hydraulic pump; max working pressure; checking and adjusting........2347
Hydraulic pump; power control; checking........2349
Hydraulic power control valve; replacing........2352
Hydraulic pump P1; removing........2354
Hydraulic pump P1; installing........2357
Hydraulic pump P2; removing........2360
Hydraulic pump P2; installing........2363
Hydraulic pump P3; removing........2366
Hydraulic pump P3; installing........2369
Servo system; specifications........2372
Servo pressure; checking and adjusting........2373
Servo pressure; at the spool in control valve; checking_{09-22-21}........2376
Servo pressure; at the spool in control valve; checking_{09-22-00}........2380
Servo valve; control; adjusting........2382
Accumulator; checking (pressure back-up for servo circuit)........2385
Servo accumulator; removing........2387
Accumulator removed; checking........2389
Servo accumulator; installing........2391
Servo valve; removing........2393
Servo valve; installing........2397
Accumulator; discarding ........2401
Boom Suspension System; component description........2403
Boom Suspension System; description........2406
Boom Suspension System; tightening torques........2412
3rd_4th hydraulic function; specifications........2413
Boom suspension accumulator; checking and adjusting........2414
Boom suspension system; hydraulic oil pressure in accumulators; depressurizing........2418
Boom suspension system; pressure reduction; safety valve; checking and adjusting........2421
Boom suspension system; test drive with load........2423
Accumulator; boom suspension system; discarding........2425
Boom suspension accumulator; reconditioning........2427
3rd; alternatively 3rd_4th hydraulic function; description........2430
3rd_4th hydraulic function; pressure; checking and adjusting........2431
3rd_4th hydraulic function; solenoid valve; replacing........2433
3rd_4th hydraulic function; shock valve; checking........2435
92 - MECHANICAL EQUIPMENT_ATTACHMENT........2438
Hydraulic attachment bracket; description........2439
Attachment locking; checking........2444
94 - UNIT; LOAD HANDLING........2445
Lift cylinder; tightening torques........2446
Tilt cylinder; tightening torques........2448
Lift cylinder; repacking in machine........2450
Tilt cylinder; repacking in machine........2457
99 - MISCELLANEOUS........2462
Fire suppression system; specification........2463
Fire suppression system; component location........2464
Fire suppression system; functional description........2466
Fire suppression system; component description........2470
Fire suppression system; actions after manual activation........2477
Fire suppression system; actions after activation........2495
Central lubrication system; description_{09-04-34}........2511
Central lubrication system; description_{09-04-12}........2516
Pump unit; description........2519
Shift valve; description........2522
Pressure monitor; description........2524
Dosage valves; description........2526
Automatic lubrication system; specifications........2530
Recommended lubricants........2532
TP-Linkage's bearing points........2534
Diagnostic tools; description........2536
Parameter settings........2538
Software; parameter settings and read-outs........2540
Automatic lubrication pump unit; reconditioning........2547
Filling lubricant........2569
Bleeding air........2571
Change of lubrication interval........2577
System test........2579
Update of automatic lubrication system........2581
Volvo L120F Wheel Loaders Repair Service Manual
